Crossing-wire fixing structure

ABSTRACT

It is a crossing-wire fixing structure  1  that comprises a first wire  12  and a second wire  13 , which each have a conductor  10  covered with an insulating coating  11  and which are arranged in such a way as to cross each other, and that also comprises a crossing portion  14 , in which the insulating coatings  11  melt and solidify so that the conductors  10  of the first wire  12  and the second wire  13  are in contact with each other, a soft material  15  adapted to cover the first wire  12  and the second wire  13  around the crossing portion  14 , a protective film  16  adapted to support the soft material  15  by interposing the first wire  12  and the second wire  13  in a radial direction thereof. The crossing portion  14  is fixed to a predetermined mounting face  17  through the protective film  16 . This fixing structure  1  has a through hole  18  provided in the protective film  16  in such a manner as not to interfere with the first wire  12  and the second wire  13 , and in such a way as to permit the soft material  15  to be exposed therefrom. The crossing portion  14  is fixed onto the mounting face  17  through the soft material  15  exposed from the through hole  18.

TECHNICAL FIELD

The present invention relates to a fixing structure for fixing crossedwires.

BACKGROUND ART

Hitherto, a conductor fixing jig and a welding apparatus including thisjig have been proposed in, for example, JP-A-9-29445 as applications oftechniques for welding conductors, which are arranged like a lattice, toone another at intersection points thereof.

As illustrated in FIG. 7, this conductor fixing jig and the weldingapparatus including this jig are constructed so that accommodatinggrooves 53 for positioning and holding conductors 52 on the top surfaceside of a body 51 of a fixing jig 50 are formed in a lattice-like form,and that through holes 55, into which a pair of chips 54 of a resistancewelder or an ultrasonic welder are inserted, are formed at intersectionpoints of the accommodating grooves 53. The conductors 52 are welded toone another while the conductors 52 are press-contacted with one anotherby being positioned and held in the accommodating grooves 53 byinserting the chips 54 into each of the through holes 55 from both aboveand below, respectively, during a state in which the conductors 52 arepositioned and held in the accommodating grooves 53.

However, the conventional conductor fixing jig and the welding apparatusincluding this fixing jig described in JP-A-9-29445 have encountered theproblems that the fixing jig 50 has no means for mounting the jig 50 ona vehicle and thus should be mounted thereon by using adhesive tapeseparately prepared, and that an operation of mounting the jig 50thereon takes time and effort.

DISCLOSURE OF INVENTION

The invention is accomplished in view of the aforementioned problems.Accordingly, an object of the invention is to provide a crossing-wirefixing structure that needs to prepare no additional mounting means andthat can be mounted on a vehicle without taking time and effort.

To achieve the foregoing object, according to the invention, there isprovided a crossing-wire fixing structure having a first wire and asecond wire, which each have a conductor covered with an insulatingcoating and are arranged in such a way as to cross each other, crossingportions, in which the insulating coatings melt and solidify so that theconductors of the first wire and the second wire are in contact witheach other, a soft material adapted to cover the first wire and thesecond wire around the crossing portion, and a protective film adaptedto support the soft material by interposing the first wire and thesecond wire in a radial direction thereof. The crossing portion is fixedto a predetermined mounting face through the protective film. Thisfixing structure further comprises a through hole provided in theprotective film in such a manner as not to interfere with the first wireand the second wire, and in such a way as to permit the soft material tobe exposed therefrom. Furthermore, the crossing portion is fixed ontothe mounting face through the soft material exposed from the throughhole.

According to such a crossing-wire fixing structure, the crossingportions of the first wire and the second wire are bonded to themounting face through the soft material forced out from the through holethe protective film when the conductors of the first and second wiresare welded to each other. Thus, there is no need for separatelypreparing additional mounting means, such as an adhesive tape. Moreover,an operation of mounting a fixing jig on, for instance, a vehicle isfacilitated.

Further, the through hole may be provided in the edge portion of theprotective film. In this case, there is eliminated the fear that theprotective film peels off the fixing structure from the edge portionthereof.

The fixing structure may have a concave portion provided in the mountingface so that the soft material exposed from the through hole isaccommodated in the concave portion. In this case, the soft material isprevented from spreading around the protective film.

Furthermore, the soft material may be a hot melt.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a sectional view illustrating a first embodiment of theinvention.

FIG. 2 is a view illustrating a process of constructing the firstembodiment of the invention.

FIG. 3 is a view illustrating a process of constructing the firstembodiment of the invention.

FIG. 4 is a view illustrating the process of constructing the firstembodiment of the invention.

FIG. 5 is a sectional view illustrating a second embodiment of theinvention.

FIG. 6 is a sectional view illustrating a third embodiment of theinvention.

FIG. 7 is a view illustrating a conventional conductor fixing structureand a welding apparatus including this fixing structure.

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of a crossing-wire fixing structure aredescribed with reference to the accompanying drawings.

FIG. 1 is a sectional view illustrating a first embodiment of theinvention. FIGS. 2 to 4 are views each illustrating a process ofconstructing the first embodiment of the invention. FIG. 5 is asectional view illustrating a second embodiment of the invention. FIG. 6is a sectional view illustrating a third embodiment of the invention.

First Embodiment

As illustrated in FIG. 1, the crossing-wire fixing structure of thefirst embodiment of the invention is applied to the case that a crossingportion 14, in which electric wires 12 and 13 cross each other, is fixedto, for example, a predetermined mounting face 17 of a vehicle.

That is, this crossing-wire fixing structure 1 has the first wires 12and the second wires 13, which each have a conductor 10 covered with aninsulating coating 11 and are arranged in such a way as to cross oneanother, the crossing portions 14, in each of which the insulatingcoatings 11 melt and solidify so that the conductors 10 of thecorresponding first wire 12 and the corresponding second wire 13 are incontact with each other, a soft material 15 adapted to cover the firstwires 12 and the second wires 13 around the crossing portions 14, and aprotective film 16 adapted to support the soft material 15 byinterposing the first wires 12 and the second wires 13 in a radialdirection thereof.

Further, this fixing structure 1 further comprises a through hole 18provided in the protective film 16 in such a manner as not to interferewith the first wire 12 and the second wire 13, and in such a way as topermit the soft material 15 to be exposed therefrom. Furthermore, thecrossing portions 14, in each of which the corresponding first wire 12and the corresponding second wire 13 cross each other, are fixed ontothe mounting face 17 through the soft material 15 exposed from thethrough hole 18. The through hole 18 is provided in an edge portion ofthe protective film 16.

Next, a method of manufacturing this crossing-wire fixing structure 1 isdescribed hereinbelow. First, as illustrated in FIG. 2, the wires 12 and13 of two flat cables 20 and 21 to be connected to each other areseparated from one another by cutting each of the flat cables 20 and 21open by a predetermined length from an end thereof, and then insertedinto grooves 23, 23 provided in a lattice-like form in a welding jig 22.

Subsequently, each of the crossing portions 14 (see FIG. 1), in each ofwhich the corresponding wires 12 and 13 cross each other, is pushed fromboth above and below by a pair of chips 24, 24 of a resistance welder oran ultrasonic welder.

Thus, as illustrated in FIG. 3, the conductors 10, 10 of the wires 12,13 crossing each other in each of the crossing portions 14 are welded toeach other. At that time, the insulating coatings 11 covering theconductors 10 melt, so that the conductors 10 are exposed.

Thus, when the welding is performed on the crossing portions 14, 14, ineach of which the corresponding wires 12 and 13 cross each other, theinterval between each pair of adjacent welded parts is maintained at aconstant value by the rigidity of each of the wires 12 and 13.Consequently, the melted parts are prevented from interfering with eachother. Upon completion of welding of the wires 12 and 13, the remainingportions of the flat cables 20, 21 are pulled out of the welding jig 22.

On the other hand, as illustrated in FIG. 4, soft materials 15 having apredetermined thickness and a predetermined length are applied onto theprotective film 16 having a predetermined length, in which the throughhole 18 is provided, at two places. Then, the welded parts of the wires12 and 13 and surrounding parts are put on one of the soft materials 15.Thereafter, a half part of the protective film 16 is turned up therebyto put the other soft material onto the wires 12 and 13.

Consequently, the wires 12 and 13 are bonded to the protective film 16through the soft material 15 by a force having a certain degree ofstrength.

During this state, as illustrated in FIG. 1, the wires 12 and 13 and theprotective film 16 are put on the mounting face 17. Then, heat andpressure are applied thereto from above the protective film 16. Thus,the soft material 15 is strongly bonded to the wires 12 and 13.Moreover, a part of the soft material 15 is forced out of the throughhole 18 provided in the protective film 16 and bonded to the mountingface 17.

Consequently, the crossing portions 14, 14, . . . , 14, in each of whichthe corresponding wires 12 and 13 cross each other, are reliably fixedonto the mounting face 17.

Butyl rubber and hot melt may be used as the aforementioned softmaterial 15. In the case of using butyl rubber, it is sufficient toapply only pressure thereto. However, in the case of using hot melt, itis necessary to apply both heat and pressure thereto.

Further, it is preferable that the through hole 18 is provided at aplace in such a way as to avoid contact with the wires 12 and 13.

Thus, according to the crossing-wire fixing structure 1 of theinvention, the crossing portions 14, 14, . . . , 14, in each of whichthe corresponding wires 12 and 13 of the flat cables 20 and 21 arewelded to each other, can be fixed to the mounting face 17 by the softmaterial 15 forced out of the through hole 18 of the protective film 16.Consequently, there is no need for preparing an adhesive tape, which isprepared in the case of using the conventional fixing structure, and anoperation of mounting a fixing jig is facilitated.

Further, because the through hole 18 is provided in the edge portion ofthe protective film 16, the protective film 16 can be prevented frompeeling off the fixing structure from the edge portion thereof.

Moreover, the conductors 10 exposed by welding the wires 12 and 13 toeach other in each of the crossing portions 14 are coated with the softmaterial 15 and the protective film 16. Thus, the conductors 10 can bereliably prevented from interfering with each other. Consequently, anoccurrence of leak can be prevented. Moreover, waterproofing of theconductors 10 is enabled.

Incidentally, although the protective film 16 is twice-folded in theaforementioned embodiment, it is possible that two protective films 16are prepared, and that the crossing portions 14, in each of which thecorresponding wires 12 and 13 cross each other, are interposed by thefilms 16 from above and below. Further, in the case that the thicknessof the soft material 15 is larger than a total thickness of the firstwire 12 and the second wire 13, the soft material 15 may be provided onthe protective film 16 only at a place.

Second Embodiment

FIG. 5 illustrates a crossing-wire fixing structure 3, which is a secondembodiment of the invention. This crossing-wire fixing structure 3 isconfigured so that through holes 18 are provided in the protective film16 at two places, and that when the protective film 16 is folded back,the through holes 18, 18 are disposed at both end portions of thefolded-back protective film 16. That is, both end portions of such aprotective film 16 are bonded to each other by the soft material 15. Therest of the second embodiment is similar to the corresponding part ofthe fixing structure 1 that is the first embodiment.

In the case of the third embodiment, the protective film 16 can beprevented from becoming loose. Moreover, the protective film 16 can bestrongly fixed.

Incidentally, the through holes 18 may be provided at three places ormore.

Third Embodiment

FIG. 6 illustrates a crossing-wire fixing structure 4, which is a thirdembodiment of the invention. This crossing-wire fixing structure 4 isconfigured so that a concave portion 25 of a predetermined size isprovided in the mounting face 17, and that a part of the soft material,which is forced out of the through hole 18 of the protective film 16, isaccommodated in the concave portion 25.

In this case, the part of the soft material, which is forced out of thethrough hole 18 of the protective film 16, can be prevented fromspreading to the outside of the protective film 16. Thus, a goodexternal appearance of the fixing jig can be realized.

Incidentally, although the case of welding end portions of the wires 12and 13 to each other has been described in the foregoing description ofthe first to third embodiments, the invention may be applied to the caseof welding middle portions of the wires 12 and 13 to each other.

INDUSTRIAL APPLICABILITY

As described above, according to the crossing-wire fixing structure ofthe invention, the crossing portions, in each of which the correspondingfirst wire and the corresponding second wire are bonded to the mountingface through the soft material forced out from the through hole theprotective film when the conductors are welded to each other. Thus,there is no need for separately preparing additional mounting means,such as an adhesive tape. Furthermore, an operation of mounting a fixingjig on, for instance, a vehicle is facilitated.

Further, in the case that the through hole is provided in the edgeportion of the protective film, there is eliminated the fear that theprotective film peels off the fixing structure from the edge portionthereof.

In the case that the concave portion is provided in the mounting face,and that the soft material exposed from the through hole is accommodatedin the concave portion, the soft material can be prevented fromspreading around the protective film. Thus, a good external appearanceof the fixing jig can be realized.

1. A crossing-wire fixing structure comprising: a first wire and asecond wire, which each have a conductor covered with an insulatingcoating and are arranged in such a way as to cross each other; acrossing portion, in which said insulating coatings melt and solidify sothat said conductors of said first wire and said second wire are incontact with each other; a soft material adapted to cover said firstwire and said second wire around said crossing portion; a protectivefilm adapted to support said soft material by interposing said firstwire and said second wire in a radial direction thereof, said crossingportion being fixed to a predetermined mounting face through saidprotective film; and a through hole provided in said protective film insuch a manner as not to interfere with said first wire and said secondwire, and in such a way as to permit said soft material to be exposedtherefrom, wherein said crossing portion is fixed to said mounting facethrough said soft material exposed from said through hole.
 2. Thecrossing-wire fixing structure according to claim 1, wherein saidthrough hole is provided in an edge portion of said protective film. 3.The crossing-wire fixing structure according to claim 1, wherein saidmounting face has a concave portion, and said soft material exposed fromthe through hole is accommodated in said concave portion.
 4. Thecrossing-wire fixing structure according to claim 1, wherein said softmaterial is a hot melt.